System for processing and packaging milk and other beverages

ABSTRACT

A system and process for packaging fluid products such as milk and other beverages is disclosed. The fluid product is produced when required and in response to a customer order. For example, milk is received and stored in a raw milk storage silo and separated into two varieties having different butter fat content. A customer order is processed and the system creates labels and fills containers or bottles exactly to meet the customer requirements. The products are palletized and loaded for shipment to the customer. Preferred filling equipment locates a container on a load cell to measure a predetermined amount of the first variety of milk into the container. The container is then filled with a second variety of milk by weight, if necessary, before capping. A supervisory control system directs bottle making, labeling, filling, bundling, and palletizing with virtually no inventory of empty bottles, preprinted labels, finished or prepackaged product inventories. The system and process provides a micro dairy that applies these features to a warehouse distribution network.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Ser. No. 09/858,026 filed May 15,2001, now U.S. Pat. No. 6,371,172, which is a divisional of Ser. No.09/408,633 filed Sep. 30, 1999, now U.S. Pat. No. 6,247,507.

This application claims priority from provisional application Serial No.60/102,491, filed Sep. 30, 1998.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to the art of beverage processing, andmore particularly to processing beverages in the dairy industry.Processing involves standardizing or mixing various grades of milk(e.g., skim, 1%, 2%, 3.25% and others) and filling them, as well asother beverages such as juices, fruit drinks, chocolate milk, intosuitable packaging or containers for sale to consumers. The containersare filled with milk and beverages in a sequence dictated by customerorders and distribution routes.

2. Discussion of the Art

Today's dairy industry has made strides in improving the efficiency ofprocessing and filling operations. The focus of these improvements hasbeen in processing and filling speeds, in the handling and storage oflarge volumes of specific products and in the order picking and loadingprocesses associated with customer requirement fulfillment.

For example, U.S. Pat. No. 5,687,779 describes a filling system thatutilizes large storage tanks (bowls) which provide a constant headpressure for servo pumps and valves to control the amount or volumeplaced in containers. Co-axial fill nozzles permit filling and mixing orstandardizing of milk (e.g., the mixing together of varying ratios ofskim and 3.25% milk to produce the intervening grades) from a singleorifice. However, these filling features limit the ability forflexibility in the filling operation. While these prior art fillingsystems are capable of filling multiple sizes very effectively, they arevery complex in terms of operation, cleaning, and maintenance.Furthermore, they standardize and fill volumetrically, and this does notpermit rapid changes in filling from one milk type (e.g., 2%) to anothermilk type (e.g., 1%). The inability to have instant changeover limitsthe flexibility of the filling operation in a manner that will notpermit a process output specifically in line with a customer order. If acustomer orders just one unit of a particular grade of milk, existingsystems will not allow for the building of orders to the accuracy ofsuch one unit per shipping order. Volumetric filling is still furtherlimited with respect to the smaller size packages such as the thirty-two(32) ounce sizes and under.

The storage, loading and order selection systems have tapped theautomated storage and retrieval and the distribution center technologiesto improve the manual processes used decades ago.

Examination of the dairy products processing, manufacturing anddistribution business (excluding hard cheese) in the United States findsa focus on the white milk segments. Approximately fifty to sixty percentof the product these businesses ship is, by volume, white milk. To avery great extent, this will include white milk with varying milk fatcontents of 3.25%, 2%, 1%, ½% and skim (non-fat).

The general process which these businesses follow starts with thereceipt of raw milk which is temporarily stored in large tanks prior toprocessing. Storage in these vessels is limited by law to a maximum timeof 72 hours. This milk is then processed into a variety of otherproducts of which the white milk category is the largest segment. Invirtually all instances, the next processing step is one of several heattreatment processes defined by the Food and Drug Administration and thePasteurized Milk Ordinance. Examples of these processes are noted asfollows:

a) High temperature Short Time Pasteurization—processing at a minimum of161° F. for a minimum of 15 seconds (typically refrigerated code life of10 to 25 days).

b) UHT (Ultra High Temperature) processing for extended shelflife—processing at a minimum of 280° F. for a minimum of 2 seconds for arefrigerated life of 45-60 days.

c) UHT Processing and Aseptic Packaging—processing at a minimum of 284°F. for a minimum of 4 seconds for a non-refrigerated life ofapproximately 180 days.

It is also understood that combinations of UHT processing, standard HTST(High Temperature Short Time) pasteurization and separation andfiltration technologies are becoming additional desirable alternativesto strictly high temperatures to achieve longer code life in bothrefrigerated and non-refrigerated products. In this instance, theundesirable microorganisms are physically removed from the various skimmilk portions while the high fat portion is UHT processed. Afterrecombination, a long life product is achieved without the negativeeffect of standard UHT processing. Generally included in each of thepasteurization processes is a standardization process. This processincludes the conversion of raw milk at a varying fat test over 3.25% toa fat test for the specific type of milk desired (i.e., 2%, 1%, etc.).

Each type of milk is then processed as a batch and stored in largeholding tanks for packaging. These tanks and the processing systemstypically are run in the batch mode for long periods of time, limitedonly by the regulatory agency requirements of cleaning and sanitizing atleast once following a 24-hour processing day.

The filling process also occurs with a batch orientation. Generallyspeaking, the systems are arranged and operated such that individualfillers will draw a particular type of milk from one of the pasteurizedstorage vessels for a significant period of time. During this time, thefiller will run estimated amounts for certain types of customers. Inother instances, when an order is provided, exact amounts may bepackaged.

In either case, the filler is packaging one product and one label at atime. When a different product is required to pass through the fillingprocess, the system must be evacuated to prevent mixing of products.This results in down time, lost products, and lost packaging, etc.

In addition to product changes, the process requires label changes basedon the needs of a specific customer. For example, a dairy may have 2%milk with its own brand and it also may have many other private labelsidentifying specific customer brands. This implies additional changes,manual intervention on processes and inefficiency.

The process of filling batches, attempting to run long batches to avoidexcessive product and label changes, and the variability of customerrequirements ultimately leads to substantial storage and finishedinventory requirements. These inefficiencies have generally led the wayfor many of the current improvements such as using large automatedstorage systems to handle long continuous runs, large batches and largeinventory requirements.

Looking at these current businesses from an order fulfillmentperspective, it is clear that a variety of categories of requirementsexist. Certain businesses have “captive customers” and can “dictate” anorder fulfillment process that they currently consider optimal. This mayinclude restrictions on order amounts, carrying inventory at storelevel, etc. Other businesses have customers who demand flexibility butprovide little or no advanced information. These systems require thebusiness to maintain inventory for the customers to assure an availablesupply as well as maintain a reasonable level of manufacturingefficiency. Despite the attempts at “just in time”, none of the currentsystems have managed to eliminate large and complex material handlingsystems to handle the processed finished inventories or the inadequaciesof the order fulfillment process.

The order fulfillment process includes distribution systems ofsubstantial magnitude and cost. This aspect of current businesses alsoplaces demands on the manufacturing and storage processes. It is theoptimization of the entire process that has further led to the notion oflarge buffer storage and ready availability through storage. Invirtually all instances, large capital intensive storage facilities andmaterial handling systems have been the apparent solution to theoptimization of processing, packaging, order selection, and distributionsystems.

The past improvements to or developments for industry problems havefocused on individual elements of the order fulfillment process.Instances are available to demonstrate bigger and faster fillingmachines to reduce the labor cost of packaging. Instances can be shownwhere expenditures have been made to improve the interface betweenhigh-speed manufacturing and complex delivery systems to certaincustomers. It is apparent that current processing and improvements havenot addressed the order fulfillment process as a comprehensive,continuous process. It would be desirable to develop a beverageprocessing and filling system that effectively meets the requirements ofthe entire order fulfillment process. This demands a system thateliminates the need for long batch type filling, large inventoryrequirements, and complex capital intensive material handling systemsfor milk and other beverages.

It would be further desirable to develop a system that would allow forfilling milk and other beverages based on a truck loading and deliveryschedule. In order to eliminate or significantly reduce the need forstorage, the filling sequence would fill various grades and volumes ofmilk, along with other beverages, and place them on pallets for deliveryrouting according to the requested order, i.e., products will beproduced and made to order at the proper time, speed, and in the exactquantities requirement by distribution for load out.

SUMMARY OF THE INVENTION

The present invention contemplates a new and improved system, whichovercomes all of the above-referred problems and others and provides afilling method, which is efficient, economical and versatile.

An advantage of the present invention is that the processing and fillingof milk and other beverages is done according to a truck loading ratebased on customer orders.

Another advantage of the present invention is found in the dramaticreduction or elimination of inventory. Labor intensive picking andloading steps are reduced; as is the amount of waste due to expiredshelf life. Only a small amount of buffer storage is suggested (on theorder of 10% of the current inventory).

Yet another advantage of the present invention is the capability ofintegrating the processing with grocery and food service distributioncenters. The truckload can contain the grocery or retail store's orderfor various products including milk. In the past, milk orders have beendelivered to stores separately from other grocery items, directly fromthe dairy instead of the grocery distribution or warehousing centers.

Yet another advantage of the present invention is the method of filling.This method fills two wide range milk components in appropriatequantities to produce exact product specifications in a continuousoperating mode. No change time or product drainage is required.

The system also provides for flexibility in labeling.

In addition, order lead time from the customer is based on truckdeparture/loading time. Orders can arrive minutes before loading, beinserted into the filling queue and then be processed. This aids inminimizing inventories at the storage level.

Packaging is done according to incoming orders. The products are filledby weight instead of volume to reduce shrinkage.

Still other advantages and benefits of the invention will becomeapparent to those skilled in the art upon a reading and understanding ofthe following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangementsof parts, a preferred embodiment which will be described in detail inthis specification and illustrated in the accompanying drawings whichform a part hereof.

FIG. 1 is a general flow diagram that presents an overview of a flexiblefilling process in accordance with the present invention.

FIG. 2 is a flow diagram representing the flexible filler in accordancewith the present invention.

FIG. 3 illustrates the “print and apply” flexible labeling process inaccordance with the present invention.

FIG. 4 is a plan view of a flexible filler in accordance with thepresent invention.

FIG. 5 schematically shows the integration of the flexible manufacturingsystem into the distribution process in accordance with the presentinvention.

FIG. 6 is a schematic representation of the flexible manufacturingprocess integrated into the plant supervisory control system inaccordance with the present invention.

FIG. 7 depicts a typical display in a retail store and the factorsaffecting replenishment.

FIG. 8 illustrates how a customer order is translated to theconfiguration requirements for pallets of finished product.

FIG. 9 lists a typical customer order broken down into palletconfigurations.

FIG. 10 is a flow diagram representing a conventional milk process.

FIG. 11 is a flow diagram representing the simplification achieved bythe flexible manufacturing process in accordance with the presentinvention.

FIG. 12 illustrates the conventional method for the milk supply chainfrom the farm to the store.

FIG. 13 shows the simplified milk supply chain from the farm to thestore in accordance with the present invention.

FIG. 14 is a plan view of a micro dairy facility in accordance with thepresent invention.

FIG. 15 illustrates how a micro dairy might be integrated with anexisting distribution facility in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will be made to the drawings which illustrate the presentinvention in the environment of a dairy that allows the manufacturer ordairy to package liquid products in a manner that optimizes the orderfulfillment process. The products are produced only when they arerequired and only to satisfy a customer order, and not before. Productswill be produced in the quantity requirements and at the rate requiredto load them onto a delivery vehicle for a customer. The result is amuch simpler manufacturing process, greatly reduced inventory levels, adramatically lower total manufacturing cost, and a low distributioncost.

The manufacturing system of the present invention is based on deliverysystem requirements. This anticipates the most effective delivery systemand the manufacturing systems to effectively supply it. If the deliverysystem demands variable rates of loading, variable numbers of vehiclesbeing loaded at a given time, and variable pallet configurations, allare available to maintain the delivery and customer requirements. Thesystem also utilizes the standard bottles that allow for other productsto be stacked on top of the product which in turn maximizes the deliveryprocess.

FIG. 1 is a flow chart that describes the basic process utilizing thecurrent invention. Milk is received, for example, by a truck 20, storedin a raw milk storage silo or tank(s) 22, processed by conventional ornew technologies as represented at 24, and is standardized to a non-fator a skim component and to a high fat (3.25% fat or above) component.These individual products are stored in separate pasteurized storagevessels 26 a and 26 b. Separate supply lines 28 a and 28 b extend fromeach vessel to transfer the product to a filling system 30. The fillingsystem, with information from the customer information system, labelsand fills bottles or containers exactly to meet the customerrequirements. The products are then palletized as referenced at 32 andloaded at 34 directly onto an available delivery vehicle or truck.

FIG. 2 provides a general flowchart of the filling system of the presentinvention. This system has customer information or requirements in termsof product type, brand name, ingredient information, nutritionalinformation, color requirements and in many cases specific labelrequirements that are input at 40. A label is printed in the appropriatesequence at a flexible labeler 42, and is applied to the bottle as itpasses through the label application device. The information on thelabel includes a UPC (Uniform Product Code) barcode which is scanned at44 and product type is identified. Other means to identify the bottlecould also be used, such as optical character recognition and visionsystems. A control system 46 for skim filling dispenses the appropriateamount of skim milk into the bottle. The bottle proceeds next to thehigh fat filling system 48. This system dispenses the appropriate amountof high fat product into the bottle. The bottle moves to a cappingstation 50 and then to the bundling and palletizing units.

Varying types of milk are mixed directly in containers by fillingcalculated weights of skim and high fat milk. For example, a 3-literbottle filled with milk weighs approximately 3,000 grams. With theapproximate weight in mind, the appropriate “X” and “Y” values (whereinX is a weight of skim milk and Y is the weight of 3.25% milk) for thevarious products are as follows:

Final Product X grams Y grams Skim 3000 0 1% 2110 891 2% 1172 18283.25%   0 3000

The filling equipment is programmed with the weights of the various milkgrades and volumes. The container moves through the system, and theappropriate weight portion of milk is directed therein.

The containers are filled using a filling valve or orifice. Duringoperation, the container is filled to a predetermined amount. Generally,this amount corresponds to a final desired content based on weight,volume, depth or other measure. A sensor of the desired measure providesfeedback to the filling orifice. The feedback signals the orifice toclose. This stops the flow into the container. For example, in the casewhere the fill is based on weight, a scale will send a feedback signalto the filling orifice to close the valve once the desired weight isachieved. Of course other sensors that are based on different measurableparameters can be used without departing from the scope and intent ofthe present invention.

FIG. 3 illustrates the labeling process. This process has unlabeled andappropriately oriented bottles 60 entering a label application device62. As the unlabeled bottle enters the applicator, customer requirementinformation directs the label printing unit to print a specific labeland a specific sequence of labels, as has been determined by customerand delivery optimization requirements. Unprinted labels are supplied tothe printer; the printer discharges a stream of labels, which areconveyed, to the label applicator. Alternatively, rolls of labels in theproper sequence to fulfill a customer's order could be prepared inadvance of producing the order. This could be accomplished bypreprinting the roll of labels, or splicing together preprinted labelsin the proper sequence. The label applicator applies the sequencedlabels to the unlabeled bottles. The now labeled bottles 64 are directedto the filling process.

FIG. 4 is a diagram of the actual flexible filling process as it wouldoccur on a Serac filler modified to incorporate two filling bowls inaccordance with the present invention. The oriented bottle 70 enters thefiller and is metered into the first transfer turret by a metering screw72. At this point, the label on the bottle is scanned for theinformation that identifies the product to be filled. The labelinformation allows the filling system to access the exact productinformation for this particular product from the control system for thefilling process. A first transfer turret 74 locates the bottle under thenonfat milk fill system 76 and onto a platform containing a load cell.This load cell and the control system of the filler act to measure apredetermined amount of the nonfat milk into the bottle. When the bottleis secure on the filler turret 76, the control system opens the valve toallow product to flow into the bottle until the exact amount is entered.The control system then shuts the fill valve and the bottle istransferred from the nonfat fill turret via a second transfer turret 78to a high fat milk fill turret 80. The control system and platform loadcell system associated with the high fat fill system adds the finalamount of high fat milk to the bottle. The filled bottle containing thestandardized product is removed from the high fat fill turret by a thirdtransfer turret 82. This turret transfers the filled and standardizedproduct bottle to preliminary and final capping stations 84, 86,respectively. These stations may use conventional capping techniques ormay use additional techniques receiving caps or pour inserts fromhoppers 88 through feed lines 90 to provide added features to thepackage. An additional transfer turret 92 transfers the finished productfrom the filler to a discharge conveyor 94, which in turn carries theproduct to the bundling and palletizing areas.

FIG. 5 conceptually illustrates the integration of this flexiblemanufacturing system into a distribution process. The manufacturing cell100 (substantially as described above), operating and responding to thecustomer requirement information system, discharges filled and closedproduct (bottles) to a wrapping/bundling system 102 in a sequence thatexactly matches the distribution requirements and the customerrequirements as needed for consumer satisfaction and optionaloperational efficiency. Without losing the predetermined sequence, theproducts are palletized at station 104 to provide a specific pallet witha predetermined mixture of nonfat, ½%, 1%, 2% or 3.25% product on eachlayer. Each pallet may also have a varying number of layers. Forexample, one pallet may only have three layers and a third pallet mayhave four layers. The final determination is based on the optimizationof the customer requirements and distribution processes.

The application of the present invention to meet the order fulfillmentrequirements of the dairy industry's operations has been illustrated inFIG. 6. This illustrates the control and operation of this flexiblemanufacturing approach in a more fully integrated environment. Thecustomer information, which is part of the business information 110, issupplied to a supervisory control system 112. This control systemmaintains and directs a bottle making system and process 114, labelingsystem and process 116, the filling and capping system and process 118,the bundling system and process 120, and the palletizing system andprocess 122. Additionally, the system monitors the process to ensureproper sequence is maintained and provides a coordinated label printingfor the completed pallet prior to the issuance to delivery system 124.The supervisory control system is in constant communication with thebusiness control system. The result is that prioritized information issupplied to the supervisory control enabling the coordination ofcompleted pallets that exactly match the priorities of loading anddelivery schedules. This is all achieved with virtually no inventoriesof empty bottles, of preprinted labels, finished or pre-packaged productinventories, and standard palletizing or product configurations thatforce unnecessary and undesirable constraints on distribution orcustomers.

The application of the present invention is further explained byexamination of the customer requirements and the information generatedat the customer level as exemplified in FIG. 7 (FIGS. 7A and 7B). FIG.7A illustrates a typical display 130 in a retail store and the factorsaffecting replenishment. The display consists of 50% to 60% of theavailable space for the large volume items that constitute approximately60% to 70% of the dairy product sales. These products typically includethe four or five major milk items represented by display portion 132.The remainder 134 of the display is made up of approximately one hundredother items that constitute the remaining 30% or 40% of the sales. Theorder fulfillment criteria are the available display space, the deliveryfrequency, the level of cash register sales, and non-display inventoryand certain external factors such as weather, time of month, etc. Thesefactors may translate into an order to the supplier, manufacturer orwarehouse as indicated. This example states that the order fulfillmentprocess at store level requires three hundred sixty three units of 3.25%product. Because there are two units in a bundle, the order is roundedup to three hundred sixty four units or one hundred eighty two bundles.Similarly, the 2% order became three hundred sixty nine bundles, the 1%order is one hundred sixty two bundles and the skim or nonfat milk orderis one hundred sixty nine bundles.

FIG. 8 illustrates the transformation that would take place as a resultof the customer requirements. In this case, the palletizing requirementis only that full layers be made on a pallet. As a consequence and sincea standard 40×48 grocery pallet will allow for sixty two units or thirtyone bundles on a layer, the total number of layers is calculated asfollows: $\begin{matrix}{3.25\% \text{-}} & \text{one hundred eighty two (182) bundles} \\{2\% \text{-}} & \text{three hundred sixty nine (369) bundles} \\{1\% \text{-}} & \text{one hundred sixty two (162) bundles} \\\text{Skim -} & \text{one hundred sixty nine (169) bundles} \\{Total} & \text{eight hundred eighty two (882) bundles}\end{matrix}$

This equates to 882/31=28.45 layers. This further suggests that thetotal layers sent will be 29, as we would choose to round up. For thisexample, we will add the 2% only. Therefore, the dairy may shipseventeen (17) additional bundles of 2% milk.

The twenty nine (29) layer example could be shipped in seven (7)-four(4) layer pallets and one (1) layer pallet. It could also be shipped asfive (5)-five (5) layer pallets and a four (4) layer pallet, or as five(5)-four (4) layer pallets and three (3)-three (3) layer pallets.

FIG. 8A shows the five individual layers for a pallet. With thirty one(31) bundles per layer, there are one hundred fifty five (155)individual bundle locations on the pallet. Each can be filled with anindividual product based on the customer requirements.

FIG. 8B also shows a plan view of the retail stores display 140 and thereserve storage 142 behind the display. Based on this layout the productshould be palletized so proper product can be located directly behindthe product being displayed to assure maximum efficiency at the storelevel. The fact that the product is shipped in a “caseless” manner meansthat no space has to be reserved to maneuver empty cases and that nolost motion is required on the part of the store's employee during there-stocking process. With this consideration, the pallets could beloaded as indicated in the table shown in FIG. 9.

This configuration could also be changed to accommodate otherdistribution constraints. An example would be to ship other products ontop of the pallets of milk. This is practical due to the caseless natureand strength of the caseless bottle as shown and described in commonlyowned, co-pending application Ser. No. 09/114/244, filed Jun. 29, 1998,the details of which are incorporated herein by reference. Based onthis, the twenty nine (29) layers may become nine (9)-three (3) layerpallets and one (1)-two (2) layer pallet. The distribution of productsper pallet would obviously change to accommodate the total needs.

As is indicated by the previous example, the present invention has theability to flexibly fulfill customer requirements based on optimalscenarios. A common feature among the full service dairy manufacturersand distributors is that approximately 60% of their daily throughput isthe white milk described as 3.25%, 2%, 1%, ½% and skim milk. It is alsotrue that these manufacturers create large batches of these white milkproducts. They currently fulfill customer requirements through processessimilar to, if not exactly as shown schematically in FIG. 10. Thisprocess begins with raw milk being received and temporarily stored insilo tanks 150. Raw milk will be withdrawn through the raw silo tanks150, pasteurized and standardized at 152 into large vessels 154 a-e tohold each type of pasteurized and standardized product (3.25%, 2%, 1%,etc.). Filling machines 156 will then draw from the various pasteurizedproduct tanks, one product at a time, and put a specific type of milkinto a specific pre-labeled bottle (i.e., 2% milk into brand X package).These containers are then put into returnable cases (or transportdevices) or corrugated one way shippers. The product is then sent to astorage or distribution center type of system 158. The product iscollected from storage 158 based on orders from customers. It is picked,selected, accumulated or somehow assembled into a load that will be putonto a delivery vehicle with a usual mission of only delivering thedairy products from that particular dairy warehouse or distributor asrepresented at 160.

The present invention provides a revised approach for the 60% to 70% ofthe volume of products typically handled by the full servicemanufacturers and provides an improved approach to the manufacturers whoare virtually only white milk manufacturers today. FIG. 11 shows theschematic of the revised manufacturing process. Raw milk is received andtemporarily stored in raw storage vessels 170. Raw milk is drawn fromthe vessels and is processed into a nonfat and a high fat components 172a and 172 b only. These two components are blended together at 174 basedon customer and delivery needs, palletized and directed to the load outfacility 176 in a manner synchronized with the proper loading time ofthe vehicle(s) 178.

The present invention, as applied and described above, provides animproved approach to the delivery of milk and other refrigeratedproducts associated with the grocery store business.

FIG. 12 illustrates the current method of bringing milk in its raw statefrom the original source (the farm), to the grocery store or the finalretail businesses that makes the product available to the consumer. Themilk is produced on a farm 180 and shipped via insulated tank truck tothe dairy 182, where it is processed in the conventional manner as shownand described above. The product is then shipped directly to the storein certain instances as represented by numeral 184. It is also shippedas represented by numeral 186 to various distributors or warehouses 188,where it is re-loaded and re-shipped, to the final retailer 190.

The present invention allows and promotes the use of an improvedapproach as illustrated in FIG. 13. This approach provides for thedirect transfer of the raw product from a source 200, or farm, to amicro dairy 202 associated with a warehouse or primary distributionsupply 204 to the store or food retailers 206. This allows theadvantages of the flexible filling invention to be applied to thewarehouse distribution network. The use of the structural caselesspackage as described in the commonly owned, co-pending applicationidentified above and the flexible filling system shown and describedherein permits the integration of traditional warehouse products withthe white milk products constituting maximized delivery efficiency. Thisis realized based upon the low maximum weight and cube in a warehousedelivery vehicle and on the improved frequency of delivery for theretailer.

This current invention further allows for the development of anintegrated micro dairy facility to be operated in conjunction with awarehouse or distributor of even smaller proportions as compared tocurrent industry standards. FIG. 14 illustrates such a facility capableof successfully completing all functions as needed for the warehouse ordistribution facility. For example, a receiving bay 220 receives the rawmilk into the micro dairy facility. The raw milk is processed at a rawmilk treatment station 222. This provides the two grades of milk whichin the preferred embodiment are 3.25% and skim. The processed milk isstored and subsequently forwarded to filling station 224 where it iseasily conveyed to the filler as described above. Control room 226handles or coordinates the actions of the micro dairy includingreceiving data regarding raw milk input, processing control, productionof various sized containers or bottles at a blow molding station 228,labeling at station module 230, filling at 224, and palletizing andshipping at 232.

FIG. 15 further shows a typical application of this micro dairy facility240 as a small addition to a typical warehouse 242 that would bedistributing product to a retail grocery outlet. As noted, this conceptapplies to both small and large distribution applications.

It can be seen that there are many advantages for manufacturers in thisapproach. Processing of different milk grades is reduced down to twotypes: skim and 3.25%. The need for large storage tanks for thedifferent milk grades is likewise reduced. Since the filler bowls willeach have only one product in them for the entire production day,changeovers are eliminated, thereby reducing labor and waste. Finally,since the filler is completely responsive to the needs of thedistribution department, load out is simplified, and the requiredwarehouse space is vastly reduced. Overall, the entire manufacturingplant process is greatly simplified, is reduced in size, and reduced incomplexity.

Accompanying this concept, a high hygiene and highly reliable filler isanticipated. A filling system includes the filler and the high-speedlabel printing process described. This system has the followingattributes:

Accurate filling of two or more components into the same container toget variable attributes from the flexible process.

The ability to change product without loss of efficiency. In otherwords, a system able to change without interrupting or haltingproduction.

The ability to produce product accurately and exactly as customerrequires.

The ability to integrate and interpret commands from the control systembased on customer requirements into labeling and filling commands toexactly meet the customer expectations.

The ability to match the variable demands of loadout processes withoutdepending on excessive inventories. This surplus drastically reducesstorage space compared to conventional manufacturing techniques.

The invention has been described with respect to the preferredembodiments. Modifications and alterations will occur to others upon areading and understanding of this specification. It is intended toinclude all such modifications and alterations in so far as they comewithin the scope of the appended claims or the equivalents thereof.

Having thus described the invention, it is now claimed:
 1. A process forpackaging milk comprising the steps of: providing empty, individualcontainers to a filling system; filling the individual containers fromat least one of first and second milk varieties; closing the individualcontainers at a capping station; and assembling the filled containersonto pallets without cases.
 2. The process of claim 1 including the stepof processing raw milk into first and second milk varieties.
 3. Theprocess of claim 2 wherein the filling step includes the step ofproviding four or more different types of milk from the first and secondprocessed milk varieties.
 4. The process of claim 3 wherein theproviding step includes using only the first processed milk variety toform the first type of milk.
 5. The process of claim 4 wherein theproviding step includes using only the second process milk variety toform the second type of milk.
 6. The process of claim 5 wherein theproviding step includes using selected amounts of the first and secondprocessed milk varieties to form the third and fourth types of milk. 7.The process of claim 6 wherein the providing step includes using agreater proportion of the first processed milk variety to form the thirdtype of milk.
 8. The process of claim 6 wherein the providing stepincludes using a greater proportion of the second processed milk varietyto form the fourth type of milk.
 9. The process of claim 1 including thestep of supplying first and second containers of different capacity. 10.The process of claim 1 wherein the assembling step includes stacking thefilled containers without cases on a pallet and wrapping the containerstogether on a pallet for shipment to the customer.
 11. The process ofclaim 1 further comprising the step of labeling the individualcontainers in response to a command from a control member detailinginformation regarding the container size, customer, and type of milk.12. A process for producing milk for sale and consumption, comprisingthe steps of: receiving raw milk into a raw milk storage station;pasteurizing the raw milk; separating the pasteurized milk into firstand second milk varieties of different milk fat content; fillingindividual containers a) from the first and second milk varieties and b)from varied proportions of the first and second varieties; closing thecontainers at a capping station; and assembling the filled containersonto a pallet without cases.
 13. The process of claim 12 wherein theassembling step includes wrapping and bundling the containers.
 14. Theprocess of claim 12 further comprising the steps of receiving an orderfrom a customer, inputting the order into a supervisory control systemand controlling the filling and assembling steps in response to theorder from the supervisory control system.
 15. The process of claim 14further comprising the step of monitoring the milk production processand supplying information to the supervisory control system.
 16. Theprocess of claim 14 further comprising the step of labeling thecontainers in response to an order from the supervisory control system.17. The process of claim 14 further comprising the step of formingcontainers in response to the order from the supervisory control system.18. The process of claim 12 further comprising the step of connecting amicro dairy to a warehouse.
 19. The process of claim 12 wherein thefilling step includes the step of exactly matching filling to a customerorder.
 20. The process of claim 12 wherein the container filling step isachieved by weighing the first and second milk varieties as introducedinto each container.
 21. The process of claim 12 wherein the fillingstep includes the step of providing four or more different types of milkfrom the first and second processed milk varieties.